Document vOvVxQNnjgM1JKdyXLLVR53b

tt i r C * KONSAHTO COMPANY Plastics Division Springfield, Massachusetts PROCESS SAFETY AUDIT 85 pngPOH ii TO: A.J. Balboni R.A* Barkhuff, Jr, V,P, Brower R.A. cofreyL^-* R.E. Cunnings W,F. Gabel M.G. Harvey D.H. Howe A.V. Laakso H.M. Deeper J.L. Shriver G.W. Salth W,P. Willis . ,V' PREPARED B7: DATE: r _ o- "" Lv-' 1 <\ a !n\ U * J<);r; D.S. Pra2er MAY 1965 f c* (f" /r ., <* :/' / ' > 0a &A sv- * /S 9+ : yJZ; J, -: -'v' ^' _j- o - ?,r' 1 e y ' V- /,V jj -s* s' C'` 4 ^ >s//_ # '* ' `r //V./ r. >A'-* t ,' i cy' 5 V <* " h--r, y;lu -<f ^ U w ^4 . >1 k<`.1 /) yr^' RSV 0008874 <A d' : I. XHTEOOTCTIGH H. SUMMARY AMD C0NCI3JSI0JTS III. SUMMARY OP PROCESS SAFETY HAZARDS XV. RAW MATERIAL HAZARD SUMMARY V REFEREICES C RSV 0008875 I i?7T?>Grucnoff A process safety audit of 85 Building operations was under taken to insure conversion of current technology for produc ticn of PVC Film and Compounds into aafa manufacturing operations. II. sraaua? Aim cckcihstcns 85 Building is strietly a physical processing area, and does not contain the sane type of hazard nomally associate with a chenical plant. There are essentially no volatile or explosive sstcrials handled, and.-no chcnical reactions take place during norsal processing. The Audit vaa'aizied at answering the following questions; 1. What are 'the hazards of the raw materials used, and.are proper handling procedures in effect? 2. What hazards exist if the process is upset by operator error or equipment malfunction, and have proper safeguards teen taken? 3. Are the emergency procedures in effect adequate to safely operate the process? In practically all cases, it was found that adequate .procedures are in effect and proper processing safe guards have teen taken.' The areas requiring upgrading and additions to procedures are tabulated in Section III along with recozssndstions, responsibilities, and target datea far conn?ni--?. Section IV "contains a listing or an raw'materials used and the tonicity and flammability hazard of each. RSV 0008676 PC^Sm-L HAZARDS COMMENTS Materials 1. slipping 5: toxicity hazard from spillage. Eetter handling of G--2 for Rigid Compound required. Mors emphasis on immediate cleanup required. Mechanical* seals on plasticizer pumps desirable. ? p 2* Possible plasticizer & stabilizer splashes into eyes. Eye wash station needed in 4th floor color weigher area. P- 3. Dusting or hazardous materials from blenders 4. Easy ignition of Eyphos stabilizer. Formal exhaust duct clean ing schedule needed. f Continued monitoring of usage and highlighting of hazard required. f 5. Toxicity of raw materials. Continued emphasis on personal hygiene, and personnel"training necessary. Adequate personnel protective equipment is available and used. o * 6. Exhausting toxic dusts to the yard area in the rear of 85 Build!ns. The possibility of exhausting toxic dusts on personnel or areas frequented by personnel to the rear of 85 Building exists. Samples of residue in various locations at the rear of the building should be taXen and analyzed for lead to determine the extent (if any) of the problem. f * E.- Processing 1. Mischarge cf blender. Materials are cocpatsble and no chemical reaction hazard existsfl Use of an excess of a toxic material could present a fuming hazard but adequate blender ventilation exists if ducts are in good condition. See Item A-3. RSV 0008877 PQgareZAL HAZARDS COMMENTS B, frocasslng (continued) 2. Degradation of mater ial in the Benbury due to operator error or equipment malfunction* Fuse respirators are avail able at Banbury and Kill Rolls* A Scott Air Pak should be placed at both calender strainers for use on the first floor. 3. Dusting of toxic materials at Banbury during cleaning, Respirators are available a -f Continued review of toxic r hazards required. 4, Slippage at Banbury areas due to oil, water, and material leakage. Housekeeping in the Banbury area requires mors shift to shift emphasis. A positive solution to stopping or con taining oil leaks is necessary, especially at #2 Banbury. 5. Rupture of Banbury Mixer due to water in the premix or mixing chamber. Although this possibility exists, it is remote. The present Banburys are loose fitting enough to relieve the type of pressure buildup that could be encountered in the operation. Consideration should be carefully given to this problem, however, if a close fitting ram is ever contemplated. This`hazard should be periodically reviewed with all operators. 6. Excessive fusing at calenders or mill rolls. All duct3 equipped vith steer, snuffers for fire protection. Exhaust ducts need periodic cleaning and a formal clean ing schedule should be established. 7. Degradation of stock in the strainer due to power failure or plugged screen. A Scott Air Pak should be provided at both the strainers. Procedure for handling this situation should be reviewed with foremen and operators. 8. Rupture of Sunertherm or Hydrothem" system due to operator error or malfunction. Both systems are adequately protected with relief valves and vented enclosures in critical areas, operating procedures 5: training are adequate for heating and c.oolir.g systems. Q? SAFITT KAIAFDS C: i C (f PL'T^ilTlAL HAZARDS ra^ggsing (continued) cck-sss q . Spontaneous ignition oily rags or Stearic Acid contain ing rags in contact with oil and plasti cizer, 10. Utility Failure. Hetal containers for dirty rag3 are located through out the building and emptied daily. Cans need repainting and restenciling with "Dirty Rags". Failure of utilities do not present any process associated hazard other than steels degradation. Respirators are available if furies become uncomfortable and evacuation and emergency procedures cover the situa tion adequately. Instruments are fail safe. C. Emergency Procedures 1. Kan caught in a calender or mill roll. Current release teas of four selected men per crew is unwieldly because of rapid personnel changes. Reccssiend training each foreman and Farrel calender operator in the release procedure with these personnel directing the removal of anyone caught in the equipment. Review should be every 6 months, and at the change of any of these personnel. Communications to and from other areas in the event of an emergency in any South plot area, A formal system should be established to insure good end prompt communications. IV. TABULATION OF RAV MATERIAL gAZAHDS The following table lists all of the raw materials currently in use in 8p Building and the tonicity and flaBsmbility hazards of each. Listings of raw materials in the groups noted 3 "Plasticisers", "Lead Stabilisers", etc. follow the tabulation. In a few cases, no positive tonicity information was available because actual toxicity tests have not been mace. In these cases, tonicity hazards were based on what information was avails^. RSV 0006879 17. TAETTuATTOrT 0? HAWV.AT5KIAI* HAZARDS (Continuea; Current tsv matsrial handling practices in 85 Building are considered adequate to safely handle these materials. Coveralls are worn by personnel with exposure to the hazards of the materials and strict eating and vashup rules are adhered to. Goggles,' respirators, and rubber gloves are available for use when the situation warrants and the personnel are well educated to the hazards involved. definition of hazard degree are as follows: Slight - Readily reversible changes which disappear after end of exposure. Moderate - May involve both irreversible and reversible changes; not severe enough to cause death or serious, pemanent, physical Impairment. High - May causa death or permanent injury after very short exposure to small quantities* W MATERIAL Plasticisers FORM Liquids Lead Stabilisers Powders TOXICIT? No appreciable hssard FLAKMABILI'TT Not easily lgnitec but will bum cn contact with flams High ingestion hazard. Moderate inhalation hssard* Slight absorp tion hasard* Highly toxic fumes when sub jected to fire. No appreciable hazard exceot Dyer which will bum ar support its own combustion. Ea, Cd, Zn, Stabilisers C Fillers Karnes, lubri cants, and miscellaneous rubber com pounds Liquids, and Powders Powders Flakes, Liquids, Powders, and Solids. High to moderate in- * gestion and inhala tion hasard. Moderate irritant hasard. Highly toxic fumes when subjected to fire. Liquids have relatively low fla point (125*F) find will bum on cents with flame. No appreciable hasard No appreciable has No appreciable hasard Not easily ignited but will bum on contact with flame Pigments r Powders High to slight in _ Dust explosion gestion and inhala hazard for some tion hazard depend pigments. ing on pigment. Highly toxic fumes when sub jected to fire. KSV 0000880 17. r'ABITLATICN C? ?JX iATERIAL KAZARTS (Continue vaTERIAI._______ j_______ FORM I__________ toxicity___________I ` i- Ultraviolet scrseners UY9f UV531, Tinopal PCR? Powders Ho positive toxicity information but most likely not hazardous No appreciable hazard Antimony Oxide, Oneor 23A Powder Highly toxic ingestion hazard. Moderate in halation hazard. Moderately toxic fumes when subjected to acid or fire. No appreciable hazard. Agerite Stalite Liquid C High to moderate inhalation and in gestion hazard. Moderate irritant hazard. Not easily ignit but will bum cr contact with fl Barium Stearate Powder Slight hazard No appreciable hazard. Calcium Stearate Powder No appreciable hazard No appreciable hazard. * Carbon* Black Powder Slight toxicity and irritant to eyes and mucous membranes Lust explosion hazard. Ethyl Cellulose N100V r Ferro Stabilizer 5221 Powder Liquid No positive toxicity information. Most likely not hazardous High to moderate Inhalation and in gestion hazard. Moderate irritant hazard Moderate firs hazard. Lust explosion hazard Not easily irr.it but will bum or* contact with fin. Fungicides Biomet =5, #6, tt21, Permaches P? Liquids High absorption, in gestion and inhalation hazards. Moderate irritant hazard. Not easily igr.it but will cum cr. contact with fin Acryloid K12CN Powder No appreciable hazard Lust explosion hazard ~ Hark XX, Triphenyl Phosphite Liquids Moderate ingestion, irritant, and inhala tion hazards. Highly toxic fumes when heated to decomposi tion Not easily igr.i^ but will bum v contact with fin Fisv 000888 1 tV "r^-syf.-TTH 0? RAtf *. .-SgAL 5A2AKD5 (csatlsued) f j ^ otesric Acid \t E " Thermo lite < and T26 1 *- FORM Flakes Liquids Tinuvin P Tricctyl phosphate Tricr-zyl Phosphate Bisphesol A Powder Liquid Liquid Powder CN-=S Powder Wool Bottoms (Mired plasti cizers and stabilizers)' Anti-yellow Agent A-8 Liquid Powder Advastab TMlSO Advastab TE918 - Liquid Cardinal CZ~A v. . Liquid Torrcnr Slight hazard ! PIJLMMJLPTr.T"* Slight hazard but will spontaneously heat High to moderate inhalation, and ingestion, hazard. Moderate irritation ' hazard* Not easily ignited but will bum on contact with flame No positive toxicity information. Moderate hazard indicated. No appreciable hazard* No positive toxicity information. Moderate hazard Indicated. Not easily ignited but will bum on contact with flame. High ingestion hazard, codarate absorption and inhalation hazard. Not easily ignited but will bum on contact with flame. Slight toxic hazard. Moderate irritant hazard to eyes and mucous membranes. No appreciable hazard. No appreciable hazard. Dust explosion hazard with ground material. Could be toxic because of stabilizer content. See Ea, Cd, Zn, Stabilizers. Not easily ignited but will bum on contact with flame. No positive toxicity information. Moderate hazard indicated* No appreciable bazar No positive toxicity information. Moderate hazard indicated* Not easily ignited but will bum on contact with flame. No positive toxicity information. Moderate hazard indicated. RSV 0008832 i TASPIATIO?* OP HAW MATERIAL HASABDS (continued) Rav Material Greycings Adsex T6l Drapex 4,4 Epcxsl 9*5 Flexol EPO Monoplex S71 Monoplex S73 Monoplex S$0 Mobiaol L Paraplex g62 Paraplex g60 Paraplex G25 Plasticiser NTH Stalex 623 Blaster 6l? Hercoflex 707 Plasticisers Santic is er l4o Santieiser l4l Santieiser 160 Santieiser 462 Santieiser 409 Santieiser 483 HB-40 LOP DHODP LOA LIDA DZDPE LIIODA EJTDP Lead Stabilisers Basic Carbonate of White Lead (ECWL) Lytksl . Lythal XL Dyphos Lyphos XL Basic Silicate of White'Lead (BSUL) Lead Stearate LS-207 Tribase Tribase XL Tribase E Lectro 60 Lectro 60XL Lectro 77 . Scotch Laddie 810 Plissb-O-Sil C Leadstar Bariua-Cadiux-Zinc Stabilisers Ferro 5250 Mark 180 Klspel Stabiliser 1276 Ni3pel Stabiliser 12766a Mlsoel Stabiliser 1212A Mark WS Hark WS/99 Mark C Mark KCB Mark LL Mark PL Mark Q153 Mark Q139 Mark- TT Mark XI Alcoa 705 Atoaite Cacel Wite Eurgcsa #30 Clay 5?33 Clay Millicarh H Osya BLB3 Osya ESH Fillers T1 Pure R5CO Ti Pure R61Q Ti Pure F? Titsnox RA Uhitane 07.342 Unitane 0R450 Unitane 0R64O Micro Cal T3S sv 0008da3 ; ' 17. TABULATION OgJ^W.i^TZRIAL HAZARDS (continued; Raw Material Groupings Waxes. Lubricants. Miscellaneous Rubber CoBsounda Aristowax 165 Diglyeol Stearate Circosol 410 Prime1 205 Advawax 140 Acrowax C Hypaloo LD134 Chemigum N8 Paraorll 2812 Polyethylene 6a Polyethylene 629 Blvax Resin 260 Aldo MR lubricant Aldo S2031 HT Fac 442 V. REFgRENCSS 1. "Dangerous Properties of Industrial Materials'1, by N.Irving Sax, Relmhold Publishing Company, 1963* 2* Monsanto Toxicity Data Sheets 3* ' Tentative Process, Rigid P7C Compounds, August 1982 4. Miscellaneous Raw Material Manufacturers Literature and PDA Bulletins 5* "Process Safety Audit, P7C Polymerisation", by A.P. Torrensano, July 1964. 6. Discussions with the following personnel: C.F. Smith G.W. Smith T.J. Loaning A.J. Balbonl P.M. Irish V.P. Brower J.W. Ryan R.A. BarJchuff, Jr, --------- ------ f* RSV 0008884